[0001] The present disclosure generally relates to a stretch laminate.
[0002] Stretch laminates form one group of materials commonly used for the production of
hygiene articles, such as diapers. As the name suggests, these materials are actually
composites of individual components that are laminated together, through the use of
an adhesive, for example. A typical stretch laminate will attempt to combine one or
more layers of cover material with one or more layers or strands of an elastomeric
material. A stretch laminate may hereafter also be referred to as "elastic laminate"
or simply "laminate".
[0003] Complications arise in that stretch laminates are notoriously difficult and expensive
to manufacture. Considerable effort has gone into proposing new types of stretch laminates
and new methods for the fabrication of stretch laminates. In particular, a considerable
number of patents discuss the difficulties of fabricating these laminates, and the
significant and extensive steps that must be undertaken to prepare these laminates.
Thus, there is a continuing need to provide new stretch laminates, new methods of
fabricating better performing and/or cheaper stretch laminates, and new absorbent
articles that comprise such stretch laminates.
[0004] The terms "activated" and "pre-activated" refer to a process of mechanically deforming
a material in order to increase the extensibility of at least a portion of the material.
A material may be activated or pre-activated by, for example, incrementally stretching
the material in at least one direction.
[0005] The terms "adhesively bonded" or "adhesively laminated" refer to a laminate wherein
an adhesive is used to bond an elastomeric material to at least one cover layer.
[0006] The term "attached" refers to elements being connected or united by fastening, adhering,
bonding, or by any other method suitable for connecting the elements together and
to their constituent materials. Many suitable methods for attaching elements together
are well-known, including adhesive bonding, pressure bonding, thermal bonding, ultrasonic
bonding, mechanical fastening, etc. Such attachment methods may be used to attach
elements together over a particular area either continuously or intermittently.
[0007] The term "disposed" is used to mean that an element(s) is formed (joined and positioned)
in a particular place or position as a unitary structure with other elements or as
a separate element joined to another element.
[0008] The term "extensible" refers to the property of a material, wherein: when a biasing
force is applied to the material, the material can be extended to an elongated length
of at least 110% of its original relaxed length
(i.e., can extend 10%), without a rupture or breakage that renders the material unusable
for its intended purpose. A material that does not meet this definition is considered
inextensible. In some embodiments, an extensible material may be able to be extended
to an elongated length of 125% or more of its original relaxed length without rupture
or breakage that renders the material unusable for its intended purpose. An extensible
material may or may not exhibit recovery after application of a biasing force.
[0009] Throughout the present disclosure, an extensible material is considered to be "elastically
extensible" if, when a biasing force is applied to the material, the material can
be extended to an elongated length of at least 110% of its original relaxed length
(i.e., can extend 10%), without rupture or breakage which renders the material unusable
for its intended purpose, and when the force is removed from the material, the material
recovers at least 40% of its elongation. In various examples, when the force is removed
from an elastically extensible material, the material may recover at least 60%, or
at least 80%, of its elongation.
[0010] The term "joined" refers to configurations whereby an element is directly secured
to another element by attaching the element directly to the other element, and configurations
whereby an element is indirectly secured to another element by attaching the element
to intermediate member(s) which in turn are attached to the other element.
[0011] The term "lateral" or "transverse" refers to a direction running at a 90 degree angle
to the longitudinal direction and includes directions within ±45° of the lateral direction.
[0012] The term "longitudinal" refers to a direction running parallel to the maximum linear
dimension of the article and includes directions within ±45° of the longitudinal direction.
[0013] The term "recovery" refers to ability of a material to return to its original size
after it has been stretched.
[0014] The "strain" or "percent strain" of a material is calculated by subtracting the original
length from the stretched length, then dividing the result by the original length
and multiplying by 100. The percent strain is described by the equation below:
where L
0 is the original length of the stretch laminate (or elastomeric film) in an arbitrary
direction at the beginning of the stretch step, and Ls is the length of the stretched
laminate (or elastomeric film) at the end of the stretch step. A sample stretched
from an original length of 10 mm to a length of 30 mm results in a strain of 200%.
Strain can be calculated in a length direction, a width direction, or any direction
there between.
[0015] The "set" or "percent set" of a material is calculated by subtracting an original
length from a final length, then dividing the result by the original length and multiplying
by 100. The percent set is described by the equation below:
where L
0 is an original length of the stretch laminate (or elastomeric film) in an arbitrary
direction at the beginning of the stretch step, and L
f is a length of the relaxed stretch laminate (or elastomeric film) after it is relaxed
from the stretch step. A sample is stretched from an original length of 10 mm to a
length of 30 mm. Upon relaxing (removal of stress), the sample returns to 15 mm. This
results in a set of 50%. Set can be calculated in a length direction, a width direction,
or any direction there between.
The term "wrinkle" refers to a small fold, ridge or crease.
[0016] The stretch laminate according to the invention has at least one cover layer and
an elastomeric film attached to the cover layer. The elastomeric film has two surfaces
and a skin on at least one of the surfaces. In one embodiment, the elastomeric film
may also be disposed between a first cover layer and a second cover layer. The elastomeric
film has a first skin on a first surface closest to the first cover layer and a second
skin on a second surface closest to the second cover layer.
[0017] The stretch laminate has at least one anchoring zone and at least one stretch zone,
and the skin that is located in the anchoring zone has a plurality of wrinkles. These
wrinkles may also be referred to as activation stripes.
[0018] In order to produce the laminate elastic strips are laminated next to one another
between nonwoven material webs. The nonwoven material webs are supplied without pre-stretching
and joined to the strips. The laminate thus formed is then stretched transverse to
the web direction in regions rendered elastic by the laminated strips, and after elastic
relaxation is wound into a roll. Due to the stretching of the laminate, which is also
referred to as mechanical activation, the elastic properties of the laminate transverse
to the web direction of the material web (CD, "cross direction") are improved.
[0019] EP 1 686 209 A1 discloses the stretch laminate with the features included in the preamble of claim
1.
[0020] According to a first embodiment of the method to produce a laminate according to
the invention, an elastic film is stretched transverse to the web direction and, after
elastic relaxation, is cut into strips. The strips are laminated next to one another
between nonwoven material webs supplied without pre-stretching and joined to the strips.
Last, the laminate thus formed is stretched transverse to the web direction in regions
rendered elastic by the laminated strips and, after elastic relaxation, is wound into
a roll. Closure elements may be punched from the material that have an elastic center
region and less elastic end sections at both ends.
[0021] Stretching the elastic film mechanically pre-activates a component of the laminate
and results in an improvement in the stretching behavior of the laminate. The pre-activation
of the elastic film has a positive effect on the stretching force profile of the laminate
and contributes to the laminate being easily stretchable over a large stretching area
while greatly increasing the stretching resistance for a yield strength determined
by the pre-activation of the elastic film, the stretching resistance being readily
determined as the yield strength upon subsequent use of the laminate. In addition,
the elastic relaxation behavior of the laminate after strain relief may be improved
by using a pre-activated elastic film. However, the pre-activation of the elastic
film does not replace the mechanical activation of the laminate, but instead cooperates
with it synergistically. In the pre-activation of the elastic film, the film is preferably
stretched essentially uniformly over its entire width. In contrast, the stretching
of the laminate for mechanical activation is locally limited to the regions of the
laminate that are already elastic due to the laminated strips that are pre-activated
according to the invention. Due to the stretching of the laminate, fibers of the nonwoven
layers are irreversibly stretched in the elastic regions of the laminate, and bonding
of the nonwoven in the elastic regions is reduced due to fiber tears and fiber rearrangements.
This is accompanied by a renewed mechanical effect on the material of the elastic
strips, as well as a mechanical effect on localized bonds between the film surface
and adjacent fibers. Areas of the laminate between the elastic regions are not altered
by stretching the laminate and retain the properties of the nonwoven.
[0022] For purposes of the pre-activation, the elastic film is preferably stretched transversely
by 100% to 500%. These numerical values refer to the change in length of the film
transverse to the web longitudinal direction relative to the starting width of the
film. The value of 100% means that the film in the stretched state has a width that
is twice the starting width of the film. The stretching is not fully reversible. As
the result of inelastic portions of the film, after its elastic relaxation the film
has a slightly greater width than prior to the stretching. The width subsequent to
the elastic relaxation may be approximately 10% to 30% greater than the starting width
of the elastic film prior to transverse stretching.
[0023] For pre-activation of the elastic film, i.e. for the transverse stretching of the
elastic film prior to its further processing, a stretching roller system composed
of intermeshing profile rollers is preferably used. The profile rollers may in particular
be composed of multiple disks that are combined into packets, the disks preferably
being arranged equidistantly for uniform stretching transversely of the web.
[0024] After pre-activation, the elastic film is cut into strips. The strips are guided
over deflectors and may be supplied as parallel strips to a lamination unit where
the strips are laminated between nonwoven webs that are supplied on the top and bottom
faces. The elastic strips are advantageously spaced from one another. The spacing
between the strips may be set by positioning the deflectors. The nonwoven webs are
directly joined together in the gaps between the elastic strips. It is also within
the scope of the invention that the areas between the elastic strips are reinforced
by co-laminated reinforcing strips. Elastic and inelastic regions may thus be formed
in the laminate.
[0025] For the mechanical activation, the laminate may be guided through a nip between two
profile rollers, each including at least two disk packets, having a plurality of disks,
situated on an axis. The laminate is stretched in places by intermeshing disk packets
of the two profile rollers. In roller sections between the disk packets, the profile
rollers form a gap, through which the laminate is guided essentially without transverse
stretching.
[0026] Relative to the overall width of the laminated strips, the maximum transverse stretching
of the laminate for the mechanical activation corresponds to the value by which the
elastic film is stretched for purposes of pre-activation. In other words, in the area
of the laminated strips, the maximum stretching of the laminate is as great as that
of the elastic film during its pre-activation. The transverse stretching of the laminate
for the mechanical activation (relative to the overall width of the laminated strips)
is preferably 50% to 90% of the value by which the film is stretched for purposes
of pre-activation.
[0027] A film composed of a polyolefin elastomer is preferably used as elastic film. The
pre-activation of the elastic film is particularly effective when an elastic film
based on polyolefin elastomers is used.
[0028] A single-layer film or a multilayer film having an elastomeric core layer composed
of styrene-isoprene-styrene (SIS) block copolymers, styrene-butadiene-styrene (SBS)
block copolymers, styrene-ethylene/butylene-styrene (SEBS) block copolymers, polyurethanes,
ethylene copolymers, or polyether block amides may also be used as elastic film.
[0029] The nonwoven from which the cover layers of the laminate are made has fibers made
of stretchable polymers that have only slight elasticity compared to the polymer of
the elastic film. The nonwoven may be composed of melt-blown fibers, staple fibers,
or continuous fibers, the fibrous web formed from the fibers being mechanically, thermally,
or chemically bonded. In particular, spunlace nonwovens may also be used as cover
layers.
[0030] In a second method to produce a printed stretch laminate according to a preferred
embodiment of the invention, the elastic film is printed with a motif made visible
through the textile surface layer of the laminate before cutting the strips. Due to
the fact that the elastic film is provided with the imprint, even while using the
laminate that has been printed, correct alignment of the printed motif relative to
the elastic region of the laminate is always ensured. The advantage therein lies in
the fact that, when stretching the elastic strip, the printed image is evenly and
reversibly stretched along with it. Furthermore, the printed motif is visible from
the front side as well as from the back side of the laminate, for example, through
a nonwoven textile surface layer, such that the laminate is optically equally attractive
from the front as well as from the back. For example, the elastic film can be printed
with a striped motif consisting of parallel, colored stripes extending in the direction
of the web of the elastic film.
[0031] Known continuous printing methods can be used for printing the elastic film. Rotary
printing processes are preferred that allow for printing the elastic film at high
web speeds. The goal is web speeds of approximately 400 m/min. Gravure printing and
flexography methods are advantageous processes, flexography being particularly preferred
because it is possible to use one central cylinder for a plurality of color systems.
Digital printing that transfers the printed image directly from a computer into a
printing machine without the use of a static medium are not excluded. In particular,
ink-jet printing methods are conceivable that generate a printed image by deflecting
small ink drops.
[0032] The elastic film is preferably stretched transversely of the direction of the web
before the printing process, then printed after elastic retraction, and subsequently
cut into strips. The stretching of the elastic film constitutes a mechanical pre-activation
of a layer of the laminate and results in improved stretching behavior of the laminate.
The pre-activation of the elastic film has a positive effect on the course of the
expansion force and provides easy stretching action of the laminate over a large area;
and at an expansion limit that is determined by the pre-activation of the elastic
film and after which the expansion resistance increases strongly. The return behavior
of the laminate after tension is removed can also be improved if the elastic film
is pre-activated by transverse stretching before laminating it into the laminate.
Any pre-activation of the elastic film cannot replace but can only supplement the
mechanical activation of the laminate. Even when the elastic film is pre-activated,
it is still necessary for the laminate to be stretched transversely of the direction
of the web in regions that are to be rendered elastic by laminated strips.
[0033] A preferred embodiment of the method according to the invention provides that the
elastic film is stretched transversely of the web by more than 50% and has a width
after reverse expansion that is greater than the starting width of the elastic film
by 10% to 30% before it was stretched. The term "stretching" is used despite the fact
that the expansion is not completely reversible but that some plastic deformation
results in the film having a larger width following the reverse expansion. Later activation
of the laminate essentially affects the structure of the textile surface layers. The
transverse stretching of the pre-activated elastic film, on the other hand, is for
the most part reversible. The printed image that is applied to the pre-activated elastic
film thus does not undergo any further disadvantageous changes during subsequent activation
of the laminate. Correspondingly, it is possible to improve the quality of the printed
image on the elastic laminate if the elastic film is only printed following pre-activation,
during which the elastic film is expanded transversely and then released.
[0034] It is possible to use a stretch-rolling apparatus of profile rollers that mesh with
each other for the stretching action of the elastic film and/or the laminate.
[0035] Preferably a polyolefin elastomer film is used as the elastic film. When using an
polyolefin-elastomer-based elastic film, pre-activation of the elastic film is especially
advantageous.
[0036] In addition, it is also possible to use as an elastic film a single-layer or multilayer
film having an elastomeric core layer made a material of styrene-isoprene-styrene
block copolymers (SIS), styrene-butadiene-styrene block copolymers (SBS), styrene-ethylene-butylene-styrene
block copolymers (SEBS), polyurethanes, ethylene copolymers, or polyether block amides.
[0037] After pre-activation and printing, the elastic film is cut into strips. The strips
are guided across a deflector and can be supplied as parallel strips to a laminator
where the strips are laminated between the textile surface layers. The elastic strips
are position at a transverse spacing from each other. The transverse spacing between
the strips can be adjusted by the position of the deflector. In the gaps between the
elastic strips, the surface layers are directly bonded to each other. It is within
the scope of the invention to use reinforcement strips that are laminated between
the elastic strips so as to reinforce the gaps between the elastic strips. It is thus
possible to constitute elastic and inelastic regions inside the laminate.
BRIEF DESCRIPTION OF THE DRAWINGS
[0038]
- Fig. 1A
- is a cross-sectional view of a first embodiment of a stretch laminate according to
the present disclosure;
- Fig. 1B
- is a cross-sectional view of a second embodiment a stretch laminate according to the
present disclosure;
- Fig. 2
- is a SEM photomicrograph showing a cross-sectional view of a portion of an elastomeric
film that has not been pre-activated;
- Fig. 3
- is a magnified version of the SEM photomicrograph of Fig. 2;
- Fig. 4
- is a SEM photomicrograph showing a cross-sectional view of a portion of a pre-activated
elastomeric film;
- Fig. 5
- is a magnified version of the SEM photomicrograph of Fig. 4;
- Fig. 6
- is a transmitted light photomicrograph of a top view of a portion of an elastomeric
film that has not been pre-activated;
- Fig. 7
- is a transmitted light photomicrograph of a top view of a portion of a pre-activated
elastomeric film;
- Fig. 8
- is a SEM photomicrograph showing a cross-sectional view of a portion of a stretch
laminate that includes an elastomeric film that has not been pre-activated.
- Fig. 9
- is a magnified version of the SEM photomicrograph of Fig. 8;
- Fig. 10
- is a SEM photomicrograph showing a cross-sectional view of a portion of a stretch
laminate that includes an elastomeric film that has been pre-activated;
- Fig. 11
- is a magnified version of the SEM photomicrograph of Fig. 10;
- Fig. 12
- is a schematic illustration of a first embodiment of a continuous process for making
a stretch laminate according to the present disclosure.
- Fig. 13
- is a schematic illustration of a second embodiment of a continuous process for making
a stretch laminate according to the present disclosure.
[0039] Fig. 1A illustrates an embodiment of a stretch laminate 20 according to the present
disclosure. According to this embodiment, laminate 20 may include three layers: an
elastomeric film 22, a first cover layer 24, and a second cover layer 26. However,
according to other embodiments (as depicted in Fig. 1B), a laminate 20' may only include
two layers: an elastomeric film 22' and a cover layer 24'. Although the following
description will refer to the specific reference numbers in Fig. 1A, the prime versions
of those numbers relating to the two layer embodiment of Fig. 1B are also intended
to be considered by the reader. For example, when the description refers to "elastomeric
film 22 and first cover layer 24 of stretch laminate 20", it is intended that the
reader also consider the same description for "elastomeric film 22' and cover layer
24' of stretch laminate 20'."
[0040] Elastomeric film 22 and cover layers 24, 26 may be attached to each other. According
to the invention, an adhesive 30, 32 is disposed between layers 22, 24, 26. As will
be recognized, adhesive 30 may be initially disposed either on a first surface 40
of elastomeric film 22 or a surface 42 of cover layer 24, and adhesive 32 may similarly
be initially disposed either on a second surface 44 of elastomeric film 22 or a surface
46 of cover layer 26. As assembled, adhesive 30 attaches surface 40 (and thus elastomeric
film 22) to surface 42 (and thus cover layer 24), and adhesive 32 attaches surface
44 (and thus elastomeric film 22) to surface 46 (and thus cover layer 26).
[0041] While the layers 22, 24, 26 appear to overlie each other completely, this need not
be the case in all embodiments. For example, cover layers 24, 26 may extend beyond
elastomeric film 22, and may be attached one to the other where the layers 24, 26
extend beyond elastomeric film 22; alternatively, cover layers 24, 26 may not extend
to the limits of elastomeric film 22. Also, while adhesive 30, 32 appears as a continuous
layer in Figs. 1A and 1B, the adhesive may be applied as a continuous layer or in
a discontinuous pattern (such as a pattern of lines, spirals, or spots). Accordingly,
the bonding can be the full width of stretch laminate 20 or a partial width of the
laminate (e.g., intermittent or zone bonding).
[0042] Elastomeric film 22 of stretch laminate 20 includes a single layer or multiple layer
material that is elastically extensible. The elastically extensible material may be
between about 10 µm and about 100 µm, or between about 20 µm and about 60 µm, or between
about 30 µm and about 50 µm, or in some embodiments, about 40 µm, in thickness. The
elastically extensible material may comprise an elastomeric polyolefin, and in some
embodiments, a polyolefin (POE) blown film. Non-limiting examples of useful elastically
extensible materials include propylene based homopolymers or co-polymers, or ethylene
based homopolymers or co-polymers selected from the group consisting of: an elastic
random poly(propylene/olefin) copolymer, an isotactic polypropylene containing stereoerrors,
an isotactic/atactic polypropylene block copolymer, an isotactic polypropylene/random
poly(propylene/olefin) copolymer block copolymer, a stereoblock elastomeric polypropylene,
a syndiotactic polypropylene block poly(ethylene-co-propylene) block syndiotactic
polypropylene tri-block copolymer, an isotactic polypropylene block region-irregular
polypropylene block isotactic polypropylene tri-block copolymer, a polyethylene random
(ethylene/olefin) copolymer block copolymer, a reactor blend polypropylene, a very
low density polypropylene, a metallocene polypropylene, metallocene polyethylene,
and combinations thereof. Additional non-limiting examples of useful elastically extensible
materials include styrene-isoprene-styrene block copolymers, styrene-butadiene-styrene
block copolymers, styrene-ethylene-butylene-styrene block copolymers, polyurethanes,
ethylene copolymers, polyether block amides, and combinations thereof.
[0043] The elastically extensible material may comprise modifying resins. Such modifying
resins useful herein include, but are not limited to, unhydrogenated C5 hydrocarbon
resins or C9 hydrocarbon resins, partially and fully hydrogenated C5 hydrocarbon resins
or C9 hydrocarbon resins; cycloaliphatic resins; terpene resins; natural and modified
rosins and rosin derivatives; coumarone indenes; polycyclopentadiene and oligomers
thereof; polymethylstyrene or oligomers thereof; phenolic resins; indene polymers,
oligomers and copolymers; acrylate and methacrylate oligomers, polymers, or copolymers;
derivatives thereof; and combinations thereof. Modifying resins may also include alicyclic
terpenes, hydrocarbon resins, cycloaliphatic resins, poly-beta-pinene, terpene phenolic
resins, and combinations thereof. Useful C5 hydrocarbon resins and C9 hydrocarbon
resins are disclosed in
U.S. Pat. No. 6,310,154.
[0044] The elastically extensible material may comprise a variety of additives. Suitable
additives including, but not limited to, stabilizers, antioxidants, and bacteriostats
may be employed to prevent thermal, oxidative, and bio-chemical degradation of the
elastically extensible material. Additives may account for about 0.01% to about 60%
of the total weight of the elastically extensible material. In other embodiments,
the composition comprises from about 0.01% to about 25%. In other suitable embodiments,
the elastically extensible material comprises from about 0.01% to about 10% by weight,
of additives.
[0045] The elastically extensible material may comprise various stabilizers and antioxidants
that are well known in the art and include high molecular weight hindered phenols
(i.e., phenolic compounds with sterically bulky radicals in proximity to the hydroxyl
group), multifunctional phenols (i.e., phenolic compounds with sulfur and phosphorous
containing groups), phosphates such as tris-(p-nonylphenyl)-phosphite, hindered amines,
and combinations thereof. Proprietary commercial stabilizers and/or antioxidants are
available under a number of trade names including a variety of Wingstay®, Tinuvin®
and Irganox® products.
[0046] The elastically extensible material may comprise various bacteriostats that are known
in the art. Examples of suitable bacteriostats include benzoates, phenols, aldehydes,
halogen containing compounds, nitrogen compounds, and metal-containing compounds such
as mercurials, zinc compounds and tin compounds. A representative example is available
under the trade designation Irgasan Pa. from Ciba Specialty Chemical Corporation of
Tarrytown, N.Y.
[0047] The elastically extensible material may comprise viscosity modifiers, processing
aids, slip agents or anti-block agents. Processing aids include processing oils, which
are well known in the art and include synthetic and natural oils, naphthenic oils,
paraffinic oils, olefin oligomers and low molecular weight polymers, vegetable oils,
animal oils, and derivatives of such including hydrogenated versions. Processing oils
also may incorporate combinations of such oils. Mineral oil may be used as a processing
oil. Viscosity modifiers are also well known in the art. For example, petroleum derived
waxes can be used to reduce the viscosity of the slow recovery elastomer in thermal
processing. Suitable waxes include low number-average molecular weight (e.g., 0.6-6.0
kilo Daltons) polyethylene; petroleum waxes such as paraffin wax and microcrystalline
wax; atactic polypropylene; synthetic waxes made by polymerizing carbon monoxide and
hydrogen such as Fischer-Tropsch wax; and polyolefin waxes.
[0048] Elastomeric film 22 also includes at least one skin disposed on the elastically extensible
material, the skin forming at least one of the film's surfaces 40, 44. Such skin is
an extensible material and provides an outer surface to elastomeric film 22 that has
less tackiness than the underlying elastically extensible material. In some embodiments,
the skin may also qualify as an elastically extensible material, but will be less
elastic than the underlying elastically extensible material. Accordingly, when compared
to the elastically extensible material, the skin will have less recovery from the
same amount of extension. Or in other words, when compared to the elastically extensible
material, the skin will have a higher percentage set from the same percentage strain.
The skin may aid in elastomeric film 22 processablity and is between about 1 µm and
about 10 µm, or between about 3 µm and about 7 µm, or in some embodiments, is about
5 µm, in thickness. In certain embodiments, the skin that overlays the elastically
extensible material in elastomeric film 22 is a polyolefin. Non-limiting examples
of useful skin materials include metallocene polyethylene, low density polyethylene,
high density polyethylene, linear low density polyethylene, very low density polyethylene,
a polypropylene homopolymer, a plastic random poly(propylene/olefin) copolymer, syndiotactic
polypropylene, metallocene polypropylene, polybutene, an impact copolymer, a polyolefin
wax, and combinations thereof.
[0049] Exemplary elastomeric films that are useful in the stretch laminates detailed herein
(i.e., an elastically extensible material with at least one skin disposed on the surface
of the elastically extensible material) include M18-1117 and M18-1361 elastomeric
films commercially available from Clopay Corporation of Cincinnati, Ohio; K11-815
and CEX-826 elastomeric films commercially available from Tredegar Film Products of
Richmond, Virginia; and elastomeric films commercially available from Mondi Gronau
GmbH of Gronau, Germany. These exemplary elastomeric films include a single layer
of elastically extensible material with a skin disposed on both surfaces of the material.
Referring to Fig. 1A, such exemplary elastomeric films would have a skin providing
first surface 40 and a second skin providing second surface 44. However, other elastomeric
films applicable to the stretch laminates detailed herein only need to have a skin
that provides first surface 40 or second surface 44.
[0050] The cover layers 24, 26 may include a nonwoven material, including but not limited
to, spun only or spun meltblown combinations, such as SM (spunbond meltblown), SMS
(spunbond meltblown spunbond), SMMS (spunbond meltblown meltblown spunbond) nonwovens,
SSMMS (spunbond spunbond meltblown meltblown spunbound), hydroentangled nonwovens
and softbond nonwovens. The nonwoven materials may also include carded nonwovens,
such as those specially designed and manufactured to be compatible with an activation
(
e.
g., ring-rolling) process. One exemplary nonwoven material is a carded nonwoven made
from a polypropylene homopolymer. The spunbounds may also be specially designed and/or
manufactured to be compatible with an activation process. However, it is believed
that through the use of the elastomeric film according to the present disclosure,
greater flexibility in the design choices may be achieved. For example, spunbounds
may be selected for applications where only carded nonwovens were used in the past,
or thinner elastomeric films may be used with the carded nonwovens. Other improvements
in design flexibility will also be recognized by the skilled practitioner.
[0051] The basis weight of the nonwoven material may be less than about 30 g/m
2 (also referred to as "grams per square meter" or "gsm"). In fact, according to certain
embodiments, the basis weight may be less than about 27 g/m
2 . In other embodiments, the basis weight may be less than about 25 g/m
2 . In still other embodiments, the nonwoven material may have a basis weight of less
than about 24 g/m
2. The nonwoven materials may also include additives, such as, for example, CaCO
3. Woven or knitted fabrics may also be used as cover layers 24, 26 in embodiments
of the stretch laminates detailed herein.
[0052] Adhesive 30, 32 may be selected from any adhesives known to provide suitable attachment
between elastomeric film 22 and cover layers 24, 26. In some embodiments, the adhesive
may be a hot melt adhesive with a basis weight of less than about 15 g/m
2. According to one embodiment, the adhesive may be H2031 adhesive commercially available
from Bostik Inc. of Middleton, Massachusetts. One characteristic of this adhesive
is that, at 23°C, this adhesive has significant pressure-sensitive character useful
for making a stretch laminate by hand. However, this adhesive is also suitable for
use in fabricating stretch laminates from the elastomeric films and cover layers listed
above using conventional stretch laminate manufacturing equipment, such equipment
being well known in the art.
[0053] Elastomeric film 22 is mechanically pre-activated before attachment to at least one
cover layer 24, 26. The elastomeric film 22 may be pre-activated by being stretched
transversely to its web direction by more than 50%
(i.e., strain > 50%). In some embodiments, an expansion by about 100% to about 500% occurs
in relation to the starting width of elastomeric film 22. In alternate embodiments,
elastomeric film 22 may be stretched in the web direction, stretched a direction other
than the web direction or transverse to the web direction, or a combination of directions.
The term "stretching" is to point to the fact that the expansion of elastomeric film
22 is not completely reversible and that a non-elastic fraction results in the film
having a larger width following pre-activation
(i.e., the elastomeric film does not have 100% recovery, and therefore has a percent set
value). After expansion, elastomeric film 22 retracts and has a width that may be
larger by about 10% to about 30% in relation to a starting width of the film. In other
words, after the pre-activation expansion and retraction detailed below, elastomeric
film 22 may exhibit a set of about 10% to about 30%.
[0054] In addition, because elastomeric film 22 includes both an elastically extensible
material and at least one skin disposed on the elastically extensible material, and
because these materials have different elasticity and recovery properties, the pre-activation
process will physically alter these materials differently. During pre-activation,
the skin and the elastically extensible material are similarly stretched
(i.e., put under similar strain). However, after stretching, the skin and the elastically
extensible material will retract and recover differently (
i.
e., have different set values). In comparison with the elastically extensible material,
the skin is less elastic and therefore will have less recovery after stretching,
a.
k.
a., a higher set value. The skin is also much thinner than the elastically extensible
material, so when the thicker elastically extensible material retracts and recovers
after pre-activation stretching, it will force the attached skin to retract with it.
But because the skin cannot recover as much as the elastically extensible material,
the skin buckles and wrinkles. Accordingly, the cross-sectional profile and the top
view appearance of elastomeric film 22 are modified after a pre-activation process.
[0055] Figs. 2-5 are SEM photomicrographs of magnified cross-sections of elastomeric films.
These SEM photomicrographs, as well as the other SEM photomicrographs included herein,
were taken with a scanning electron microscope (Hitachi Model 3500). The information
to calculate specific magnifications and distances is included in each individual
SEM photomicrograph along the bottom of the frame. Fig. 2 is a SEM photomicrograph
taken at approximately 900X magnification showing a cross-sectional view of a portion
of an elastomeric film that has not been pre-activated. The skins are the thin strips
of contrasting material at the top and the bottom of the cross-section, with the thicker
elastically extensible material between the skins. The skin at the top of the cross-section
is easier to discern due to the cross-section being cut cleaner in that region. Without
pre-activation, the skins, and thus the outer surfaces of the elastomeric film, are
substantially smooth in a cross-sectional view. Fig. 3 is a higher magnification image
(approx. 3500X magnification) of the skin at the top of cross-section shown in the
SEM photomicrograph of Fig. 2
[0056] Fig. 4 is a SEM photomicrograph taken at approximately 900X magnification showing
a cross-sectional view of a portion of an elastomeric film that has been pre-activated.
Again, the skins are the thin strips of contrasting material at the top and the bottom
of the cross-section, with the thicker elastically extensible material between the
skins. With pre-activation, the skins, and thus the outer surfaces of the elastomeric
film, are wrinkled in a cross sectional view. Fig. 5 is a higher magnification image
(approx. 3500X magnification) of the skin at the top off the cross-section shown in
the SEM photomicrograph of Fig. 4.
[0057] Figs. 4 and 5 show that after pre-activation, the skin of elastomeric film 22 includes
a plurality of wrinkles having hills and furrows. For example, as shown in the non-limiting
sample photographed in Fig. 5, there are approximately six hills and six furrows of
varying size within the pictured approximately 35 µm of length taken along the cross-sectional
profile of the pre-activated elastomeric film. This is in comparison to Fig. 3, in
which there are no hills and no furrows within the pictured approximately 35 µm of
length taken along the cross-sectional profile of an elastomeric film that was not
pre-activated. However, as visible on the top surface of the elastomeric film shown
in Fig. 3, one or more random hills and/or furrows may be present within a particular
length of cross-sectional profile of an elastomeric film that was not pre-activated.
These random hills and/or furrows are due to irregularities in the surface of the
elastomeric film. Such random hills and/or furrows should not be confused with the
hills and furrows of the plurality of wrinkles that are intentionally formed in an
elastomeric film through a mechanical pre-activation process.
[0058] Figs. 6 and 7 are transmitted light photomicrographs of magnified top views of elastomeric
films. The transmitted light photomicrographs were taken in color using a Nikon SMZ
1500 Stereo Light Microscope equipped with an Evolution Mp5C Digital camera with white
light shining underneath the elastomeric film samples. The blue scale marks at the
bottoms of Figs. 6 and 7 are in millimeters. This scale can be used to calculate specific
magnifications and distances in the transmitted light photomicrographs. Fig. 6 is
a transmitted light photomicrograph showing a top view of a portion of an elastomeric
film that has not been pre-activated. Without pre-activation, the viewable outer surface
of the elastomeric film
(i.e., the top view of the skin), has no discernible stripes and is uniform in appearance.
Fig. 7 is a transmitted light photomicrograph showing a top view of a portion of an
elastomeric film that has been pre-activated. With pre-activation, the top view of
the skin includes a plurality of stripes in varying thicknesses that relate to the
size and pitch of the intermeshing discs of the mechanical pre-activation means. The
stripes, referred to herein as activation stripes, indicate zones in the pre-activated
elastomeric film in which there was a particular range of stretching during the pre-activation
process. For example, as shown in non-limiting sample photographed in Fig. 7, there
are medium thickness darker blue stripes indicative of a heavier intensity skin wrinkling,
large thickness light blue stripes indicative of medium intensity skin wrinkling,
and thin white stripes indicative of lower intensity skin wrinkling.
[0059] In addition, after pre-activation, but before utilizing elastomeric film 22 in the
fabrication of stretch laminate 20, the film may optionally be printed with an image
or motif that may show through the cover layers of the stretch laminate. The ink or
other pigment utilized in printing will be deposited on the hills and into the furrows
of the wrinkles of the pre-activated elastomeric film. Ink deposited onto the textured
surface of a pre-activated elastomeric film allows for more contact surface area between
the elastomeric film and the ink. Accordingly, when printing on a pre-activated elastomeric
film, there is an image that is more strongly set on the film when compared to an
image printed on the much smoother surface of an elastomeric film that has not been
pre-activated.
[0060] Moreover, when stretch laminate 20 includes a pre-activated (and subsequently printed)
elastomeric film that is mechanically activated, a non-distorted printed image on
the film is evenly and reversibly stretched along with it. This is because before
the image was printed on the pre-activated elastomeric film, a significant portion,
or the entire, non-elastic fraction of elastomeric film 22 has already been removed
in the pre-activation process. In other words, the set had been removed from elastomeric
film 22 before printing. Therefore, the printed image will not substantially distort
further with the later activation of stretch laminate 20, or in additional stretching
of the laminate by a user. In contrast, if an image or motif were printed on an elastomeric
film that was not pre-activated, and that printed film was then used in fabricating
a stretch laminate, and then the stretch laminate was mechanically activated, the
desired image would be distorted in the final activated stretch laminate. This is
because the set of the elastomeric film was not removed prior to the printing process,
and such set would be removed from the elastomeric film in the mechanical activation
of the fabricated stretch laminate, thus distorting the original printed image. Likewise,
if an elastomeric film is printed and then subsequently pre-activated, the set of
the elastomeric film will not be removed prior to the printing process, and such set
would be removed from the elastomeric film in the pre-activation process, thus distorting
the original printed image.
[0061] And in another embodiment, a pre-activated elastomeric film may be stretched again
during the printing of the film. The printed film is then relaxed and used in fabrication
and activation of the stretch laminate. The resulting activated stretch laminate has
an image or motif that is aesthetically pleasant when the stretch laminate is in a
stretched condition during use (e.g., when a user stretches the stretch laminate in
application or removal of an absorbent article).
[0062] In fabricating stretch laminate 20, cover layers 24, 26 are attached to elastomeric
film 22 through the use of adhesives 30, 32. When utilizing an elastomeric film that
has not been pre-activated, the adhesive has a relatively smooth surface in which
to adhere. Fig. 8 is a SEM photomicrograph taken at approximately 900X magnification
showing a cross-sectional view of a portion of a stretch laminate that includes an
elastomeric film that has not been pre-activated. The skin is the thin contrasting
strip of material running about midway through the photomicrograph, with the thicker
elastically extensible material below the skin. Disposed on top of the skin is an
adhesive, which is also attached to the cover layer. In this exemplary embodiment,
the fibers of the cover layer are the large cylindrical objects at the top of the
SEM photomicrograph. Without pre-activation, the skins, and thus the outer surfaces
of the elastomeric film, are substantially smooth in a cross-sectional view. Fig.
9 is a higher magnification image (approx. 3500X magnification) of the interaction
between the skin and glue as shown in the SEM photomicrograph of Fig. 8.
[0063] Fig. 10 is a SEM photomicrograph taken at approximately 900X magnification showing
a cross-sectional view of a portion of a stretch laminate that includes an elastomeric
film that has been pre-activated. The skins are the contrasting strips of material
running through the middle of the photomicrograph, with the thicker elastically extensible
material between the skins. With pre-activation, the skins, and thus the outer surfaces
of the elastomeric film, are wrinkled in a cross sectional view. Disposed on outer
surfaces of the skin
(i.e., the surfaces not contacting the elastically extensible material) is adhesive, which
is also attached to the cover layer. In this exemplary embodiment, the fibers of the
cover layer are the large cylindrical objects at the top and bottom of the SEM photomicrograph.
The pre-activated elastomeric film includes a textured skin with wrinkles in a cross-sectional
view. Fig. 11 is a higher magnification image (approx. 3500X magnification) of the
skin at the top of the elastomeric film shown in the SEM photomicrograph of Fig. 10.
[0064] As previously shown in Figs. 4 and 5, Figs. 10 and 11 also illustrate that after
pre-activation, the skin of elastomeric film 22 is textured and includes a plurality
of wrinkles having hills and furrows. Adhesive 30, 32 that attaches elastomeric film
22 to cover layers 24, 26 may flow over the hills and into the furrows of the pre-activated
elastomeric film. Accordingly, adhesive 30, 32 is disposed in the furrows of the skin
of elastomeric film 22. This is in comparison to Figs. 8 and 9, in which there are
no furrows in the elastomeric film for the adhesive to flow into. Adhesive flowing
into the furrows of a pre-activated elastomeric film allows for more contact surface
area between the film and the adhesive, leading to a stronger bond between the cover
layer and the film. Accordingly, when using the same amount of adhesive, there is
a stronger bond (
e.
g., better creep resistance) between a pre-activated elastomeric film and a cover layer
when compared to the bond between an elastomeric film that has not been pre-activated
and a cover layer. Moreover, when employing a pre-activated elastomeric film, previous
bond strengths between elastomeric films that were not pre-activated and a cover layer
may be achievable with the use of less adhesive.
[0065] In embodiments of stretch laminates that include an elastomeric film that is pre-activated
and subsequently printed, the ink or other pigment utilized in printing will be deposited
on the hills and into the furrows of the wrinkles of the film. As detailed above,
ink deposited onto the textured surface of a pre-activated elastomeric film will more
strongly set on the film due to the additional contact surface area between the elastomeric
film and the ink (in comparison to ink disposed on a elastomeric film that has not
been pre-activated). Adhesive 30, 32 that attaches elastomeric film 22 to cover layers
24, 26 may also flow over the hills and into the furrows of the pre-activated elastomeric
film. Accordingly, adhesive 30, 32 is disposed over the ink and/or in the furrows
of the skin of pre-activated elastomeric film 22. And because the ink is more strongly
set on the pre-activated elastomeric film, when using the same amount of adhesive,
there is a stronger bond (
e.
g., better creep resistance) between a pre-activated (and subsequently printed) elastomeric
film and a cover layer when compared to the bond strength between an printed elastomeric
film that has not been pre-activated and a cover layer. Moreover, when employing a
pre-activated (and subsequently printed) elastomeric film, previous bond strengths
between printed elastomeric films that were not pre-activated and a cover layer may
be achievable with the use of less adhesive.
[0066] In addition, pre-activating an elastomeric film also lowers the force needed to later
stretch the film (versus a non-activated film). This helps the later mechanical activation
of the stretch laminate because the load required to activate a stretch laminate that
is made with pre-activated film will be lower (versus a non-activated film).
[0067] The stretch laminate 20 is mechanically activated by stretching the laminate transversely
in relation to the direction of the web. The technique for forming such a stretch
laminate is generally referred to as "zero strain" stretch laminate formation. Examples
of zero strain stretch laminate formations and the resulting stretch laminates are
described in
U.S. Pat. Nos. 4,116,892;
4,834,741;
5,143,679;
5,156,793;
5,167,897;
5,422,172; and
5,518,801. In the particular zero strain stretch laminate formation detailed herein, stretch
laminate 20 may be guided through a nip between two profile rollers, each roller including
at least two disk packets having a plurality of intermeshing disks that are situated
on an axis. This process is also commonly referred to as a "ring rolling" process.
Stretch laminate 20 is transversely stretched in places by the intermeshing disk packets.
The region in which stretch laminate 20 is stretched by the intermeshing disk packets
is referred to as stretch zone 66. In the roller sections between and/or outside the
disk packets, the profile rollers form a gap, through which stretch laminate 20 is
guided though essentially without transverse stretching. The regions in which stretch
laminate 20 are not stretched by the intermeshing disk packets are referred to as
anchoring zones 68, 69.
[0068] In stretch zone 66, the fibers of cover layers 24, 26 are modified and irreversibly
stretched due to fiber tears and rearrangements. However, because stretch laminate
20 includes elastomeric film 22 that has been pre-activated, the elastomeric film
between the cover layers is not further substantially stretched during the mechanical
activation process
(i.e., a substantial amount of set is not added to the film during activation of the stretch
laminate). In other words, elastomeric film 22 has substantially the same transverse
width before and after mechanical activation of stretch laminate 20. This is because
a significant portion (or the entire) non-elastic fraction of elastomeric film 22
(
i.
e., the set value) has already been removed in the pre-activation process. Accordingly,
the expansion property of the fabricated stretch laminate 20 is improved in stretch
zones 66 in the cross-direction (
i.
e., transverse in relation to the longitudinal web direction) due to mechanical activation.
Following activation, when applying minimal force, stretch laminate 20 is easily expandable
in the cross-direction.
[0069] Thus, in mechanically activated stretch laminate 20 (which is apt to fabricate an
ear panel or other absorbent article parts), elastomeric film 22 is activated in both
stretch zone 66 and anchoring zones 68, 69. In previous stretch laminates that did
not include a pre-activated elastomeric film, the mechanically activated stretch laminate
would include an elastomeric film that was activated in stretch zone 66, but not activated
in anchoring zones 68, 69. Accordingly, the portion of the elastomeric film that was
located in the anchoring zones did not contain a plurality of wrinkles. Also, when
the viewed from the top, the portion of the elastomeric film that was located in the
anchoring zones did not include a plurality of activation stripes. Further, in previous
stretch laminates that did not include a pre-activated elastomeric film, the adhesive
bonding the elastomeric film to the cover layers was in contact with a non-wrinkled
surface on the surface of the film located in both stretch zone 66 and anchoring zones
68, 69 during fabrication. In stretch laminate 20 described herein, adhesive 30, 32
that bonds elastomeric film 22 to cover layers 24, 26 is in contact with a textured
surface having a plurality of wrinkles on the surface of the film located in both
stretch zone 66 and anchoring zones 68, 69 during fabrication, providing for increased
bond strength between the film and the cover layers.
[0070] The dimensions and values disclosed herein are not to be understood as being strictly
limited to the exact numerical values recited. Instead, unless otherwise specified,
each such dimension is intended to mean both the recited value and a functionally
equivalent range surrounding that value. For example, a dimension disclosed as "40
mm" is intended to mean "about 40 mm".
[0071] All documents cited in the Detailed Description are, in relevant part, incorporated
herein by reference; the citation of any document is not to be construed as an admission
that it is prior art with respect to the present invention. To the extent that any
meaning or definition of a term in this disclosure conflicts with any meaning or definition
of the term in a document incorporated by reference, the meaning or definition assigned
to the term in this disclosure shall govern for this disclosure.
[0072] While particular embodiments of the present invention have been illustrated and described,
it would be obvious to those skilled in the art that various other changes and modifications
can be made without departing from the spirit and scope of the invention. It is therefore
intended to cover in the appended claims all such changes and modifications that are
within the scope of this invention.
[0073] The first embodiment of the method to produce a laminate according to the invention
is explained below. Fig. 12 schematically shows the method of making an elastic laminate.
[0074] In the method shown in the figure, an elastic film 1 is stretched transverse to a
web direction in a pre-activation station, and after elastic relaxation is cut into
strips 2. The strips 2 are guided over deflectors 3, and as parallel strips are laminated
next to one another between two nonwoven material webs 4 and 5. The material webs
4 and 5 are guided above and beneath the strips 2 without pre-stretching, and are
adhesively or thermally bonded to the strips 2. The view clearly shows that the elastic
strips 2 are laminated at a spacing from one another between the cover layers, and
that the nonwoven cover layers 4 and 5 are directly joined together in the gaps between
the elastic strips 2. Elastic regions 6 and inelastic regions 7 are thus formed in
the laminate 8. The laminate is supplied to an activation unit 9, in which the laminate
8 is stretched transverse to the web direction in the regions 6 rendered elastic by
to the laminated strips 2. After elastic relaxation, the laminate 8 is wound into
a roll 10.
[0075] The elastic film 1 is stretched transverse to the web direction by more than 50%
in the pre-activation station 11. The stretching occurs essentially uniformly over
the entire width of the film 1. The elastic film is preferably stretched by 100% to
300% relative to its starting width of the elastic film, stretching to 500% also being
possible. After the elastic relaxation, the elastic film 1 has a width B
2 that is 10% to 30% greater than the starting width B
1 of the elastic film. The stretching of the elastic film 1 constitutes a pre-activation
that has an advantageous effect on the elongation values of the laminate 8. A stretching
roller system composed of intermeshing profile rollers may be used to pre-activate
the elastic film 1.
[0076] A single-layer elastomer film or a multilayer film having an elastomeric core layer
composed of styrene-isoprene-styrene block copolymers, styrene-butadiene-styrene block
copolymers, styrene-ethylene/butylene-styrene block copolymers, polyurethanes, ethylene
copolymers, or polyether block amides may be used as elastic film. An elastic blown
film composed of a polyolefin elastomer is particularly preferably used.
[0077] The stretching of the laminate 8 is limited to the regions of the laminate 8 that
have been made elastic by the laminated and pre-activated strips 2. For this purpose,
the laminate 8 is guided through a nip between two profile rollers that include at
least two packets of a plurality of disks mounted on an axle. The laminate is stretched
in places by the intermeshing disk packets of the two profile rollers. As a result
of the stretching, textile structures of the cover layers are altered in the elastic
regions 6 of the laminate, and the elongation properties of the laminate 8 in the
CD direction, i.e. transverse to the web longitudinal direction, are improved. Relative
to the overall width of the laminated strips 2, the maximum transverse stretching
of the laminate during stretching corresponds to the value by which the elastic film
1 is stretched during pre-activation. The transverse stretching of the laminate 8
relative to the overall width of the laminated strips is preferably 50% to 90% of
the value by which the elastic film 1 is stretched during pre-activation. Next to
the disk packets, the profiles have roller sections in which the laminate is not subjected
to transverse stretching. These sections define a nip through which the laminate 8
is guided essentially without transverse stretching.
[0078] The second embodiment of the method will be illustrated in further detail with reference
to a similar illustrated embodiment. Fig. 13 is a schematic representation of the
second method of making a printed, elastic laminate.
[0079] With the method shown in the figure an elastic film 1 is cut into strips 2 that are
guided across a deflector 3 and supplied to a laminator 4 as parallel strips. The
strips 2 are laminated in a laminating direction 4 between textile surface layers
5 and 6 that are fed from above and below to the strips 2. The strips 2 and the textile
surface layers 5 and 6 are glued together or connected to each other thermally. The
view in the figure demonstrates that the elastic strips 2 are laminated at a spacing
from each other between the surface layers 5 and 6 and that the textile surface layers
5 and 6 are directly connected to each other in gaps between the elastic strips 2.
This way, elastic regions 8 and 10 as well as inelastic regions 9 are created in the
laminate 7. The laminate is then supplied to an activator 10 in which the laminate
7 is stretched transversely at the regions 8 rendered elastic by the laminated strips
2 relative to the direction of the web. A stretch-roller apparatus having profile
rollers that mesh with each other is used for stretching the laminate 7. Stretching
modifies the textile structures of the surface layers, and the expansion property
of the laminate 7 is improved in the CD direction, that is transversely of the longitudinal
web direction. Following activation, the laminate is easily expandable in the CD direction
by minimal force to an expansion limit that is determined by the activation.
[0080] The textile surface layers 5 and 6 are made of, in particular, nonwoven fabric; woven
or knitted fabrics are also possible. A single-layer or multilayer elastomer film
can be used as elastic film 1 having an elastomer core layer made of styrene-isoprene-styrene
block copolymers, styrene-butadiene-styrene block copolymers, styrene-ethylene-butylene-styrene
block copolymers, polyurethanes, ethylene copolymers, or polyether block amides. An
elastic blown film made of a polyolefin elastomer is preferred.
[0081] Before cutting the film into strips 2, the elastic film 1 is printed in a printing
station 11 with a motif that is visible through the textile surface layer 5 and 6
of the laminate 7. Printing is preferably done by a rotary printing method, particularly
flexography. The printed motif can be, for example, a striped motif made of parallel
colored stripes that extend in the longitudinal direction of the elastic film of the
web.
[0082] Before printing, the elastic film 1 is stretched transversely of the web by more
than 50%. Preferably, an expansion by 100% to 500% is effected relative to a starting
width of the elastic film. After the elastic retraction, the elastic film 1 has a
width B2 that is larger by 10% to 30% than a starting width B1 of the elastic film.
Following the retraction, the elastic film 1 is printed and subsequently cut into
strips 2. Expanding and/or stretching the elastic film 1 constitutes pre-activation.
Pre-activation of the elastic film has considerable advantages with regard to the
expansion values of the laminate 7. Due to pre-activation of the elastic film 1 prior
to the printing process, it is also possible to improve the printed image of the elastic
laminate 7, the reason for this being that during stretching of the laminate 7, the
printed image is evenly and reversibly expanded along with the laminate, and pre-activation
of the elastic film 1 results in the laminate 7 completely resetting itself following
stretching in the activation apparatus 10.